Flowmeter and method

ABSTRACT

A flowmeter for detecting fluid flow rates in a pipe includes a tube having a channel disposed in the pipe through which fluid in the pipe flows. The flowmeter includes an upstream transducer in contact with the pipe and positioned so plane waves generated by the upstream transducer propagates through the channel. The flowmeter includes a downstream transducer in contact with the pipe and positioned so plane waves generated by the downstream transducer propagate through the channel and are received by the upstream transducer which produces an upstream transducer signal. The downstream transducer receives the plane waves from the upstream transducer and provides a downstream transducer signal. The flowmeter includes a controller in communication with the upstream and downstream transducers which calculate fluid flow rate from the upstream transducer signal and the downstream transducer signal. A method for detecting fluid flow rates in a pipe.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/565,341 filed Aug. 2, 2012, now U.S. Pat. No. 8,806,734, which is adivisional of U.S. patent application Ser. No. 12/653,087 filed Dec. 8,2009, now U.S. Pat. No. 8,245,581 issued Aug. 21, 2012, all of which areincorporated by reference herein.

FIELD OF THE INVENTION

The present invention is related to a flowmeter for detecting fluid flowrates in a pipe having a tube with a channel disposed in the pipethrough which fluid in the pipe flows and plane waves generated by anupstream ultrasonic transducer and a downstream ultrasonic transducerpropagate. (As used herein, references to the “present invention” or“invention” relate to exemplary embodiments and not necessarily to everyembodiment encompassed by the appended claims.) More specifically, thepresent invention is related to a flowmeter for detecting fluid flowrates in a pipe having a tube with a channel disposed in the pipethrough which fluid in the pipe flows and plane waves generated by anupstream ultrasonic transducer and a downstream ultrasonic transducerpropagate, where the tube is made of a sound absorbing material so thatessentially all non-fluid paths of sound are absorbed.

BACKGROUND OF THE INVENTION

This section is intended to introduce the reader to various aspects ofthe art that may be related to various aspects of the present invention.The following discussion is intended to provide information tofacilitate a better understanding of the present invention. Accordingly,it should be understood that statements in the following discussion areto be read in this light, and not as admissions of prior art.

The current ultrasonic flow meter arrangement uses two transducers atopposing ends of a pipe where one is upstream from the fluid flow andother is downstream from the fluid flow, both transducers transmit andreceive signals. Each transducer generates plane waves into the fluidand surrounding pipe wall. The difference in transit times between theupstream and downstream signal is used to calculate the flow rate. Sincesound travels faster in the pipe wall than in the fluid medium, thereceiving transducer has noise because the sound enters the pipe andarrives at a time preceding the sound that travels in the liquid. Thenoise level is significant because it reduces the accuracy of the flowmeasurement and results in a poor or no measurement at low flow rates.

Furthermore, traditionally, polymers with scattering fillers (such asmetal or glass or microspheres) are used as backing masses forultrasonic transducers. The use of an attenuative backing mass improvesthe bandwidth of the transmitted ultrasound signal of a transducer byabsorbing the sound from the back side of the transducer and notallowing reflections to occur. Polymers with scattering fillers, it isbelieved, have never been used as pipe wall sound attenuators in the useof an ultrasonic transit time flow measurement.

BRIEF SUMMARY OF THE INVENTION

The present invention is applicable for measuring flow rates,particularly low flow rates, with ultrasonic transit time technology.The application is specifically applied to monitoring chemical fluidinjection in subsea oil wells. The invention is directed to the use of asound absorbing tube to direct the flow. This tube attenuates sound ofall acoustic paths except that through the fluid. This improvement makespossible a flow measurement at very low flow rates through very smallbore pipes.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, the preferred embodiment of the inventionand preferred methods of practicing the invention are illustrated inwhich:

FIG. 1 shows a flowmeter of the present invention.

FIG. 2 shows an acoustic signal path.

FIG. 3 shows a low flow meter arrangement.

FIG. 4 shows a demonstration of transit time flow meter performance—a4.5 mm diameter tube with 100 cSt Oil (3 Mhz Signal).

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals refer tosimilar or identical parts throughout the several views, and morespecifically to FIGS. 1 and 3 thereof, there is shown a flowmeter 10 fordetecting fluid flow rates in a pipe 12. The flowmeter 10 comprises atube 14 having a channel disposed in the pipe 12 through which fluid inthe pipe 12 flows. The flowmeter 10 comprises an upstream ultrasonictransducer in contact with the pipe 12 and positioned in alignment withthe channel so plane waves generated by the upstream transducer 16propagate through the channel. The flowmeter 10 comprises a downstreamultrasonic transducer in contact with the pipe 12 and positioned soplane waves generated by the downstream transducer 18 propagate throughthe channel and are received by the upstream transducer 16 whichproduces an upstream transducer 16 signal. The downstream transducer 18receives the plane waves from the upstream transducer 16 and provides adownstream transducer 18 signal. The flowmeter 10 comprises a controller20 in communication with the upstream and downstream transducers 18which calculate fluid flow rate from the upstream transducer 16 signaland the downstream transducer 18 signal.

The tube 14 may be made of a sound absorbing material so thatessentially all non-fluid paths of sound are absorbed. The upstreamtransducer 16 and the downstream transducer 18 may extend through thepipe 12 wall and acoustically communicate with the pipe 12 interior. Thetube 14 may form a seal with the pipe 12 essentially preventing fluid inthe pipe 12 leaking around the tube 14.

The tube 14 may be made of a polymer filled with attenuative particles.The polymer may be either an epoxy, nylon, PTFE or PEEK(polyaryletheretherketone). The particles are either metal, glassmicrospheres, metal oxide or rubber having a size equal to or smallerthan the acoustic wavelength. The tube may have a length L and adiameter opening D such that under volume flow conditions where Q>0.2liters/hour, the tube dimensions L/D² are greater than 1385/meters whenC>1400 m/s.

The present invention pertains to a method for detecting fluid flowrates in a pipe 12. The method comprises the steps of flowing fluidthrough a channel of a tube 14 disposed in the pipe 12. There is thestep of generating plane waves by an upstream transducer 16 in contactwith the pipe 12 and positioned in alignment with the channel so theplane waves propagate through the channel and are received by adownstream transducer 18 which produces a downstream transducer 18signal. There is the step of generating plane waves by the downstreamtransducer 18 in contact with the pipe 12 and positioned so the planewaves propagate through the channel and are received by the upstreamtransducer 16 which produces an upstream transducer 16 signal. There isthe step of calculating with a controller 20 in communication with theupstream and downstream transducers 18 fluid flow rate from the upstreamtransducer 16 signal and the downstream transducer 18 signal.

The tube 14 can be made of a sound absorbing material and wherein thegenerating plane waves by the upstream transducer 16 step may includethe step of generating the plane waves by the upstream transducer 16 sothat essentially all non-fluid paths of sound are absorbed by the tube14, and wherein the generating plane waves by the downstream transducer18 step may include the step of generating the plane waves by thedownstream transducer 18 so that essentially all non-fluid paths ofsound are absorbed by the tube 14. The generating plane waves by theupstream transducer 16 step may include the step of generating the planewaves by the upstream transducer 16 which extends through the pipe 12wall and acoustically communicates with the pipe 12 interior, andwherein the generating plane waves by the downstream transducer 18 stepmay include the step of generating the plane waves by the downstreamtransducer 18 which extends through the pipe 12 wall and acousticallycommunicates with the pipe 12 interior. The tube 14 may form a seal withthe pipe 12 essentially preventing fluid in the pipe 12 leaking aroundthe tube 14.

In the operation of the invention, the current ultrasonic flow meterarrangement uses two wetted transducers at opposing ends of a tube 14 ina pipe 12 where one is upstream from the fluid flow and other isdownstream from the fluid flow, both transducers transmit and receivesignals (FIG. 1). The difference in transit times between the upstreamand downstream signal is used to calculate the flow rate. Eachtransducer generates plane waves into the fluid and surrounding pipe 12wall (FIG. 2). The propagation of the sound wave has a profile known asthe transducer beam profile.

${{For}\mspace{14mu}\Delta\; t} = {\frac{2{VL}}{C^{2}} = \frac{8\;{QL}}{\pi\; C^{2}D^{2}}}$

-   -   L: path length    -   C: speed of sound in fluid    -   V: fluid velocity    -   C>>V    -   Δt: t₂−t₁ transit time difference    -   Q: mass flow    -   D: diameter of opening

As the mass flow decreases so does the transit time difference betweenthe upstream and downstream flow. By increasing the length “L” of thetube 14 and decreasing the diameter opening “D” the effective Δt can beincreased such that Δt>0.1 ns, under low mass flow conditions theflowmeter 10 has to be designed such that the tube 14 dimensions

$\frac{L}{D^{2}}$can measure a Q as low as 0.2 liters/hour since C is a constant.

For FIG. 1:

$t_{2} = \frac{L}{C - V}$

-   -   t₁: upstream transit time    -   t₂: downstream transit time    -   L: path length    -   C: speed of sound in fluid    -   V: fluid velocity

${t_{1} = {\frac{L}{C + V}\mspace{14mu} C}}\operatorname{>>}V$$V = {{\frac{C^{2}\Delta\; t}{2L}\mspace{14mu}\Delta\; t} = {\frac{2{VL}}{C^{2}} = \frac{8{QL}}{\pi\; C^{2}D^{2}}}}$Q = V ⋅ Area  Q:  Mass  Flow  D:  diameter  of  opening$V = {{\frac{Q}{A}\mspace{14mu}{Area}} = \frac{\pi\; D^{2}}{4}}$

In order to solve for the speed of sound in fluid and fluid velocity theupstream and downstream transit times need to be measured via acontroller 20. The controller 20 computes the transit time differencesbetween the upstream and downstream flow. The Δt is then used tocalculate the fluid velocity for a given flowmeter 10 length “L” for acalculated speed of sound “C”. Once the velocity “V” has been calculatedthen the Mass Flow Q can be determined since the area “A” of the fluidopening or pipe 12 is known.

For FIG. 2:

-   -   λ: wavelength    -   Nd: focal length

$\varphi = {\sin^{- 1}\left( \frac{{.61}\;\lambda}{r} \right)}$

-   -   r: radius of the transducer

${Nd} = \frac{r^{2}}{\lambda}$

$\lambda = \frac{c}{f}$

-   -   When sound diverges at angle φ, it then propagates into pipe 12        wall which is received by the opposing transducer as noise.    -   f: frequency

Since sound travels faster in the solid pipe 12 or tube 14 wall than inthe fluid medium, the receiving transducer suffers from acoustic noisefrom the pipe 12/tube 14 acoustic paths. This acoustic noise arrives ata time preceding the sound that travels in the liquid since soundvelocities in the solid are higher than those in the fluid. This noiseis significant because it reduces the accuracy of the flow measurementand results in a poor or no measurement at low flow rates. The measureof the effect of this noise is signal to noise ratio.

In order to solve this problem, a tube 14 with acoustically attenuativeproperties is in inserted within the pipe 12 (FIG. 3). The acoustic tube14 has a small inner diameter and a large outer diameter. The opening inthe tube 14 acts as conduit for the fluid and the fluid path for sound,while the surrounding area acts as sound absorber. After the soundtravels through the conduit it begins to spread again but this has noeffect on the signal to noise ratio therefore the surrounding soundabsorber successfully disables the pipe 12 noise.

The tube 14 is made preferably of a polymer filled with attenuativeparticles, for example tungsten particles (mesh 200) with a certainvolume fraction up to 50%. The polymer can be for example epoxy, nylon,PTFE or PEEK but is not limited to these materials. The choice ofpolymer is dependent on the pressure rating of the application and itseffectiveness in working with the attenuative particles to attenuatesound. The filler can be any metal, metal oxide, or rubber with a smallmesh size, the lower the volume fraction of particle filler the higherthe acoustic attenuation. Once a cylinder is fabricated then it ismachined such that there is an inner diameter for fluid flow. The soundabsorbing tube 14 can be threaded on the OD; therefore, it screws intothe flowmeter 10. The sound absorbing tube 14 can be glued on the OD;therefore, it bonds into the flowmeter 10. The sound absorbing tube 14can either press fit or captured by clips or retainers.

Simple ultrasonic flow measurement tests have shown an improvement inthe signal to noise ratio at low flow rates. The experimental setupincluded 5 MHz frequency ultrasonic transducers separated a distance of4 inches. The tube 14 used had an inner diameter of ¼″ and outerdiameter of 1″. The tube 14 was made of epoxy with tungsten particlefiller. For test purposes olive oil was used since it has a similarviscosity to certain injection chemicals to be applied. It is noted thatthe higher the viscosity of the fluid, the more important the soundabsorbing properties become. Specifically, as the viscosity increases,the fluid path acoustic signal is attenuated and the signal to noiseratio decreases.

A flow rate of 1 liter/hour was measured and the signal to noise ratioimproved by 10 times using the attenuative tube 14. Flow rates as low as0.2 Liters/hour are readily achievable. Flow rates up to 90 liters/hourmay also be analyzed. The low flow meter enables a chemical injectionmetering valve to dispense corrosion preventing chemicals to the subseawell at a low flow rate. The low flow meter is being used for chemicalinjection, but it could also be used for any application requiring ameasurement at low flow rates. See FIG. 4 which shows a demonstration oftransit time flow meter performance—a 4.5 mm diameter tube with 100 cStOil (3 MHz Signal).

During ultrasound transmission any sound which propagates at an angleafter the transducer focal length is attenuated or absorbed within thesound absorber tube 14 walls. This allows a line of sight ultrasoundsignal to be received uninhibited from any other acoustic noise source.As a result the signal to noise ratio is greatly improved therebyenabling ultrasonic transit time flow measurements at very low flowrates that were not possible before since the SNR increased 10 timesfold. This invention will be used in a low flow meter for monitoringfluid injection in subsea oil wells.

Although the invention has been described in detail in the foregoingembodiments for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be described by thefollowing claims.

The invention claimed is:
 1. A flowmeter for detecting fluid flow ratescomprising: a pipe through which the fluid flows; a tube having achannel with a longitudinal axis disposed in the pipe through whichfluid in the pipe flows, the tube is made of a sound absorbing materialso that essentially all non-fluid paths of sound are absorbed, the tubeis made of a polymer filled with attenuative particles, wherein theparticles are either metal, metal oxide, glass microspheres or rubberhaving a mesh size less or equal to the acoustic wavelength; an upstreamultrasonic transducer having a radius r in contact with the pipe andpositioned in alignment with the channel so plane waves generated by theupstream transducer propagates through the channel in parallel with thelongitudinal axis; a downstream ultrasonic transducer having a radius rin contact with the pipe and positioned in alignment with the channel soplane waves generated by the downstream transducer propagate through thechannel in parallel with the longitudinal axis and are received by theupstream transducer which produces an upstream transducer signal, thedownstream transducer receiving the plane waves from the upstreamtransducer and providing a downstream transducer signal, the upstreamtransducer and the downstream transducer extend through the pipe walland acoustically communicate with the pipe interior; and a controller incommunication with the upstream and downstream transducers whichcalculate fluid flow rate in the pipe from the upstream transducersignal and the downstream transducer signal.
 2. The flowmeter asdescribed in claim 1 wherein the upstream transducer and the downstreamtransducer extend through the pipe wall and acoustically communicatewith the pipe interior.
 3. The flowmeter as described in claim 2 whereinthe tube forms a seal with the pipe essentially preventing fluid in thepipe leaking around the tube.
 4. The flowmeter as described in claim 3wherein the polymer is either an epoxy, nylon, PTFE or PEEK.
 5. Theflowmeter as described in claim 4 wherein the tube has a length L and adiameter opening D such that under volume flow conditions where Q>0.2liters/hour, the tube dimensions L/D² are greater than 1385/meters whenC>1400 m/s.
 6. The flowmeter as described in claim 1 wherein theflowmeter measures flow rates as low as 0.2 liters/hour through thetube.
 7. A method for detecting fluid flow rates comprising the stepsof: flowing fluid through a channel having a longitudinal axis of a tubedisposed in a pipe, the fluid flowing in the pipe and into the tube, thetube is made of a sound absorbing material so that essentially allnon-fluid paths of sound are absorbed, the tube is made of a polymerfilled with attenuative particles, wherein the particles are eithermetal, metal oxide, glass microspheres or rubber having a mesh size lessor equal to the acoustic wavelength; generating plane waves by anupstream ultrasonic transducer having a radius r in contact with thepipe and positioned in alignment with the channel so the plane wavespropagate through the channel in parallel with the longitudinal axis andare received by a downstream transducer having a radius r which producesa downstream transducer signal, wherein the generating plane waves bythe upstream transducer step includes the step of generating the planewaves by the upstream transducer so that essentially all non-fluid pathsof sound are absorbed by the tube; generating plane waves by thedownstream ultrasonic transducer in contact with the pipe and positionedin alignment with the channel so the plane waves propagate through thechannel in parallel with the longitudinal axis and are received by theupstream transducer which produces an upstream transducer signal, theupstream transducer and the downstream transducer extend through thepipe wall and acoustically communicate with the pipe interior, whereinthe generating plane waves by the downstream transducer step includesthe step of generating the plane waves by the downstream transducer sothat essentially all non-fluid paths of sound are absorbed by the tube;and calculating with a controller in communication with the upstream anddownstream transducers fluid flow rate from the upstream transducersignal and the downstream transducer signal.
 8. The method as describedin claim 7 wherein the generating plane waves by the upstream transducerstep includes the step of generating the plane waves by the upstreamtransducer which extends through the pipe wall and acousticallycommunicates with the pipe interior, and wherein the generating planewaves by the downstream transducer step includes the step of generatingthe plane waves by the downstream transducer which extends through thepipe wall and acoustically communicates with the pipe interior.
 9. Themethod as described in claim 7 wherein the flowmeter measures flow ratesas low as 0.2 liters/hour through the tube.
 10. A flowmeter fordetecting fluid flow rates comprising: a pipe through which the fluidflows; a tube having a channel with a longitudinal axis disposed in thepipe through which fluid in the pipe flows, the tube has a length L anda diameter opening D such that under volume flow conditions where Q>0.2liters/hour, the tube dimensions L/D² are greater than 1385/meters whenC>1400 m/s; an upstream ultrasonic transducer in contact with the pipeand positioned and positioned in alignment with the channel so planewaves generated by the upstream transducer propagates through thechannel in parallel with the longitudinal axis; a downstream ultrasonictransducer in contact with the pipe and positioned in alignment with thechannel so plane waves generated by the downstream transducer propagatethrough the channel in parallel with the longitudinal axis and arereceived by the upstream transducer which produces an upstreamtransducer signal, the downstream transducer receiving the plane wavesfrom the upstream transducer and providing a downstream transducersignal, the upstream transducer and the downstream transducer extendthrough the pipe wall and acoustically communicate with the pipeinterior; and a controller in communication with the upstream anddownstream transducers which calculate fluid flow rate in the pipe fromthe upstream transducer signal and the downstream transducer signal. 11.A method for detecting fluid flow rates comprising the steps of: flowingfluid through a channel having a longitudinal axis of a tube disposed ina pipe, the fluid flowing in the pipe and into the tube, the tube has alength L and a diameter opening D such that under volume flow conditionswhere Q>0.2 liters/hour, the tube dimensions L/D² are greater than1385/meters when C>1400 m/s; generating plane waves by an upstreamultrasonic transducer in contact with the pipe and positioned inalignment with the channel so the plane waves propagate through thechannel in parallel with the longitudinal axis and are received by adownstream transducer which produces a downstream transducer signal;generating plane waves by the downstream ultrasonic transducer incontact with the pipe and positioned in alignment with the channel sothe plane waves propagate through the channel in parallel with thelongitudinal axis and are received by the upstream transducer whichproduces an upstream transducer signal, the upstream transducer and thedownstream transducer extend through the pipe wall and acousticallycommunicate with the pipe interior; and calculating with a controller incommunication with the upstream and downstream transducers fluid flowrate from the upstream transducer signal and the downstream transducersignal.
 12. The method as described in claim 11 wherein the tube forms aseal with the pipe essentially preventing fluid in the pipe leakingaround the tube.